Chlorinated resins stabilized with bis-phenol compounds



United States Patent "ic 1,151

Patented Apr. 7, 1959 lliww n-butyl 'ketone or methyl isobutyl ketone. The preferred stabilizer of this class-is 2,2-di-(p-hydroxyphenyl) proe pane, also referred to herein'a's diphenylol propane.

CHLORINATED RESINS STABILIZED WITH Other-suitable compounds are- -2,2-bis(4-hydroxyphenyl) BIS-PHENOL COMPOUNDS "b'utan'e;"3,3 bis(4-hydroxyphenyl) hexane; =2,2-bis(4-hydr0xy-3 -,methylphenyl) propane; 2,2-bis(4-hydroxy-3-iso- David W. Young Homewood Ill. and Wilbur F. Fischer Cranford, N.J. assignors ti) Esso Research and Engi: propylphenyl) propane bis(z hydroxy chloro' phenyl) butane; as well as related substances. C PB f Q Q P Dglawm? These compOunds'have been used heretofore as anti- N0 Drawing- .ApplicationJuly 15,1955- 10 oxidants for ..various' hydrocarbon materials such as Serial 522,373 natural and synthetic rubber, as well as for vinylidene Claims (Cl. 2604535) chloride monomer. However, it has now been discovered that these compounds act as unusually eflective stabilizers s H for chlorine-containing aliphatic resins, since they act This invention relates to improvements'in the stabili- '1 therein not only as anti-oxidants but also, once a hydrozation of substantially saturated aliphatic compounds congen chloride molecule is split; off from the resin, they aptaining about 25 to 70 weight percent of chlorine and pear-, to alkylate directly onto the resinous polymer and having a high molecular weight, e.g. above 250, alone therebyprevent the usual breakdown of the latter. And

or plasticized or otherwise, diluted witha stable liquid apparently it is this ,allcylating ability of the stated or solid diluent. In particular, this invention relates to bisphenol compounds which sets them off from other compositions of chlorinated unbranched, straight-chain known phenolicanti-oxidants such as 2,6 -di-t-butyl-4- hydrocarbons such as polyvinyl chloride type resins, stamethyl cresol and similar di or trialkylated monocyclic bilized with a bisphenol compound such as 2,2-bis(p-hyphenols or even the ring-alkylated bisphenol compounds droxyphenyl)-propane. such as 2,2-bis(2-hydroxy-3-t-butyl-5-methylphenyl)-pro- This application is a continuation in-part of application pane. Also, as compared with most prior art stabilizers, Serial No, 168,371, filed June 15, 1950, now abandoned. the, bisphenols of the present, invention possess a great High-molecular weight chlorine-containing resin-like advantage in their relatively high molecular weight as solids such as polyvinyl chloride, vinyl chloride-acetate well as their high boiling point. I a j copolymers, polyvinylidene chloride; chlorinated poly- In accordance with the invention, the unalkylated bisethylene and chlorinated paraffin wax have been finding phenol compounds are mixed into the resin-like solid in ever increasing use .in .various fields because of theirunconcentrations ranging from 0.1 to 5 weight percent. usual flame resistance, resistance to chemicals, imperme- The invention will best be understood from the following ability to water and other numerous beneficial properties. illustrative examples. a The vinyl chloride type plastics have been used especially in sheet form for shoe soles, upholstery material, cur- Q 1 Y tains, belts, and so on, while chlorinated polyethylene ,A commercial resinous copolymer of about 95% vinyl and particularly chlorinated wax have found considerable chloride and 5% vinyl acetate was worked on a rubber popularity as coatings on duck canvas, to make the latter mill at 300 R in-the presence of 0.25 weight percent both water-proof and fire-proof. However, the utility of, of various stabilizing agents and the time within which the chlorine-containing resins ,has been] limited by their 49 the resin darkened onthe mill was taken as an indication tendencyto' split out hydrogen chloride, to depolymerize, of stabilizer effectiveness as shown in Table I. to deteriorate physically-and to discolor in an oxidizing i atmosphere, especially in sunlight. Prior efforts to com- Table I bat this instability by means ofIvarious stabilizing agents I stabflizen me o a on mill m have been only partially successful. The agents used r .1 2 '5 heretofore fall into two categories, namely, anti-oxidants 2,2 bis 2 -hy'd 3 butyl 5 h which ,take up oxygen so as to reduce its deleterious cfiect bh n l propane 10 on the resin, and various metal salts or basicallyreactive 2 2 i g hydroxy 3 t butyl 5 h 1.-

agents such as lead stearate, basic lead carbonate, dibutyl' Y h n 1) .rb

tin dilaurate and the like, which combine with the hydro 1.. 1 2 hydroxy 3 t butyl 5 hy gen chloride produced'by decomposition of the resin and i thus prevent the liberated acid .gas from exerting its harirr' ful influence on the resin; However, even the best stabil' izers heretofore known left much to be desired as totheir. These data indicate the WW decided Superiority of the ff fiveness I 2,2-bis(hydroxyphenyl)-propane over similar bisphenol A new class of stabilizers for chlorine-containing an "E I PQ S alkylatlng flbllity was Y phatic resins has now been discovered which appears -to' I- ?n of Varlous alkyl groups the ammaflc 7 goperate on a new principle. The new stabilizers usedin the present invention are bisphenol compounds having the EXAMPLE 2 v formula' R X R wh r i X i s lect d from th Chlorinated wax has been used previously as a resin: group consisting of 2,2-alkylidene groups of 3 to 6 carbon llke solid to form fiamerPl'oof Coatings, but Such P atoms, and 3,3-alkylidene groups of 4 to 7 carbon atoms, llcfs c ed proper light and heat stability- ,B p

and wherein R and R are unsubstituted hydroxyphenyl such as dip ylol P P a highly effective n 0Vefgroups, preferably para-hydroxyphenyl groups, but altero g t i ShOI't-COmiHg-EIS shown y, the following tests natively maybe monochlorinated hydroxyphenyl groups wherein a solid white, chlorinated wax having a or mono-alkylated hydroxyphenyl groups having, 1 to 3 chlorine content, obtained by chlorination of a parafiin carbon-atoms per alkyl group. Such compounds can be wax having a melting point of 132. F., was blended obtained by condensing in a known manner two mols of with varying amounts of diphenylol propane and the a simpleor a chlorine-substituted phenol with one fmol blend 'worked on a rubber mill at 300 F.,' for 'varying of a ketone such as acetone, methyl ethyl ketone, methyl 70 lengths of time and the resulting color changes noted;

Table 11 Time on rubber mill Test Amount of stabilizer No. added min. min. 30 min.

1.-- None 1- Yellow color. Brown color--. Black color. 2. 0.1% diphenylol propane do Yellow color-. Do. 3-- 0.5% diphenylol propane do do Yellow color. 4 3%diphenylol propane.- White color White colon... Do. 5 0.5% stabilizer A l Yellow color Brown color.-. Darkbrown color. 6...--- 0.8% stabilizer do do Do.

I 2,6-di-tert-buty14-methyl phenol.

The results indicate that diphenylol propane, especially in concentrations of at least 0.5%, is highly effective in preventing discoloration of chlorinated wax, whereas prior art anti-oxidants of the alkylated phenol type are relatively useless.

EXAMPLE 3 The present invention is also highly effective for stabilizing polyvinyl chloride plastics wherein chloroparaflins are used as plasticizers. The economy, availability, flame resistance and electrical properties of chloroparafiins having about 20 to 35 carbon atoms and 30 to 70 weight percent of combined chlorine have long suggested the use of these materials in chlorinated polyvinyl plastics. However, the major drawback to the application of chloroparatfins or chlorinated waxes in this medium has been the lack of suitable means for stabilizing the resulting mixtures. This has now been overcome by the discovery of the unusual effectiveness of the stated bisphenol compounds.

For instance, the effectiveness of diphenylol propane was compared with other known stabilizers in the following set of runs. Resin compounds were prepared on a rubber mill at 300 F. according to the following formula:

Parts by weight Vinyl chloride (95%)-acetate (5%) resin (Vinylite VYNW) 100 Di-octyl phthalate Chlorinated wax (40% chlorine content) 25 Clay 12 Stabilizer (as noted in Table III) 5 Obtained by chlorination of paraflin wax having 132 F. melting point.

The stability of the resulting resin compounds was tested in two ways. In one test, the stability was measured in terms of time elapsed before the compound darkened substantially while being worked on the rubber mill at 300 F. For the other test, the compounds were molded into 6" by 6" x 0.25" slabs in a rubber mold at 300 F. for 5 minutes, the slabs placed in a circulating air oven at 220 F., and deterioration with Itime was noted. The results are summarized in Table Chemical analysis: 9.17% N a, 5.21% B, 3.59% P, 7.78% Cu, 51.33% Ash.

The data once again show the outstanding effective- EXAMPLE 4 The effectiveness of diphenylol propane as a heat stabilizer for chlorinated high molecular weight hydrocarbon polymers such as chlorinated polyethylene, is illustrated in Table IV.

Table IV Composition Description Yellowish brown after 20 min.

on rubber mill at 330 F.

White after 30 min. on rubber mill at 330 F.

chloriralted polyethylene (27- Chlorinated polyethylene (27- 30% O1) plus 3% diphenylol propane.

The effectiveness of diphenylol propane in chlorinated polyethylene is quite remarkable and contrasts with the relative inefliect'iveness of this stabilizer in pure poly ethylene.

EXAMPLE 5 The bisphenol stabilizers are also useful in polymeric vinyl chloride compositions plasticized by means of nitrilediolefin polymers as illustrated in Table V.

Table V Compound (parts by weight) No. 1 No. 2 No. 3 No. 4 No. 5 No. 6

Vinyl chloride -aoetate (5%) oopolymer 100 100 100 100 100 itrilorubber 35 35 Nitrile tripolymer #1 i 35 35 N itrile tripolymer #2 35 35 Lead stearate 1 1 1 1 1 Dibasic lead phosphite. 2 2 2 2 2 Dioctyl phthalate 25 25 25 25 25 25 Diphenylol propane 0. 09 0. 09 0. 09

I; Buizadggne (65%) ecrylonitrlie (35%) oopolymer; rubber-like; Mooney v cos y Aer-ylonitrile (50%)butadiene (30%)lsobutylene (20%) tripolymer; resinous; prepared by emulsion lymerization.

'Acrylonitrile (60%) 'butadiene (30 )isobuty1ene (10%) trlpolymer; resinous; prepared by emulsion polymerization.

In making up the compounds listed above the diphenylol propane, in the form of a methyl ethyl ketone solution, was first added to the respective nitrile polymer on a cold mill and the vinyl plastic and other ingredients added thereto subsequently. The complete compounds were fluxed at 300 F. for.1 /2 minutes. Films of 0.015" thickness were calendered at 270-300 F. from all stocks. Thereafter samples of the resulting films were heat aged in an air oven at 250 F. for 8 hours and other samples of the films were tested for resistance to ultra-violet light in a Fadeometer at F. for8 hours. The results ness of diphenylol propane as a stabilizer for chlorin- 75 obtained are summarized in Table VI below.

Table VI Compound No. 1 No. 2 No.9 No. 4' No. 5 No. 6

Color after oven aging, 8 hours Dark brown. Tan. Darlfbrown- Straw color. Dark brown- Tan. Color after Fadeometer, 20 hours Brown Light brown. Tan Light tan--." Tan Light ten.

The results show that the diphenylol propane is remarkably effective in improving the color stability 'of the polymeric blends described above. In making the comparisons it is important to note that the even numbered compounds-greatly excel the odd numbered compounds which contain the conventional metal-containing resin stabilizers, Moreover, it should be noted that even the odd numbered compounds contain the usual minor amount of a conventional anti-oxidant in the form of 2,6-di-t-butyl-4-methyl phenol, which in all cases was incorporated into the respective nitrile polymers subsequently to their synthesis. show the effectiveness of diphenylol propane, but at the same time they illustrate the inability of conventional phenol-type stabilizers to overcome the color-forming tendencies of chlorinated vinyl compounds. Since in most uses of polyvinyl resins their color stability is one of the foremost considerations, the importance of the present invention cannot be overemphasized.

EXAMPLE 6 When a nitrile rubber stabilized with between about 0.5 to 5%, e.g. with 1% of diphenylol propane is hot fluxed with a polyvinyl chloride resin, severe roughening of the resulting stock occurs. This is apparently due to the fact that the highly reactive bisphenol anti-oxidant originally present in an amount entirely adequate to protect the rubber, is gradually removed from the latter by alkylation onto the vinyl chloride polymer, and the nitrile rubber, deprived of its anti-oxidant, thereafter begins to cyclize and lose its compatibility with the vinyl chloride polymer. Because of this, when polyvinyl chloride resins are plasticized with nitrile rubber it is most desirable to use both a bisphenol anti-oxidant of the type described herein as well as about 1 to 5 percent (based on the rubber) of a ring-alkylated phenol anti-oxidant such as a dibutyl cresol or a'diarnyl cresol. Though either of these types of anti-oxidant is highly effective in stabilizing nitrile rubber alone, either type alone, even when used in increased amounts, is far inferior to a combination of the two types when used in blends of nitrile rubber with a polyvinyl chloride type plastic.

The peculiar cooperation of the two types of antioxidant is illustrated by the following test wherein 100- parts of a rubbery copolymer of 65% butadiene and 35% of acrylonitrile (90 Mooney) was mixed with 200 parts of a resinous copolymer of 95% vinyl chloride and 5% 'vinyl acetate (Vinylite VYNW), 6 parts of a sodium organo phosphate known as Vanstay 16, 3 parts of lead stearate and 1 part of diphenylol propane. When the resulting stock was fiuxed at 280 to 300 F., severe roughening occurred. In contrast when 1 part of 2,6-di-t-butyl- 4-methyl phenol was added to a like stock prior to the fluxing step, toughening was avoided. Moreover, Fadeometer tests of 90 hours duration indicated no apparent color change in the case of the rubber-resin blend containing both the alkylated phenol and the bisphenolic anti-oxidant, whereas samples from the blends to which no alkylated phenol was added showed a noticeable color change. ,Conver'sely, it'has already been shown in Example 5 that the alkylated phenol alone likewise affords only inadequate protection to blends of a vinyl chloride polymer and a diolefin-nitrile polymer.

EXAMPLE 7 While in the foregoing examples diphenylol propane has been used to illustrate the merits of the present in- Thus, the results not only vention, the subsequent data show that other bisphenol compounds of the proper type are also similarly useful,

though most of them are not true equivalents of diphenylol propane because of their somewhat inferior ability to give full protection against lossof clarity.

In comparing the various. bisphenols, samples were prepared by blending the various indica ted ingredients with the polyvinyl chloride-acetate resin on a rubber mill at a temperature of 300 F. according to the following general compounding recipe:

Y Parts Polyvinyl chloride-acetate resin (Geon l01)-- 1'00 Diisooctyl phthalate 50 Q Dibasic lead stearate .1 i 2 Bisphenol (as indicated) "70,13

Table VII Oomposition Stabilizer Code 1 None- None 2,2-bisg i-hydroxyphenyhpropane A 2,2-bis 4-hydroxyphenyl)butane 1 B 2,2-bis (4-hydroxy-3-methylphenyl) propane. MeAf 2,2-bis(4-l1ydroxy-3-isopropyl phenyDprogane 03A: 2,6-b1s(2-hydroxy-5-methylbenzyl)-4-rnet yl phenol- X.

Composition No '1 2 ,3 4 5 6,

Stabilizer (code) None A B MeA 08A X Original:

Tensile, lbs./sq.in 3, 045 3,020 2,995 3, 025' 2,930 2,950 Elongation, percent--. 290 290 310 310 300 305. Modulus at 100% el ng. 2, 000 1, 995 1, 885- 1, 895 l, 885 1, 815 Light transmission, percent. 76 77 80 81 74 77 Oven aged, 4 days at 0.:

Tensile, lbs/sq 3,050 3,090 3,105 Elongation, percent... 225 276 27 260 265 280 Modulus at 0 2, 295 2,325 2, 265 2, 240 2', 350 2, Tensile retained, percent--. 87 99. 101 101 106 105 Light transmission, percent. 26 78 79 77 65 61 Oven aged, 7 days at 100 0.:

Tensile, lbs/sq. in 2, 2,980 2,920 2, 985 2,900 2,920 Elongation, percent.-- 105 265 270 275 255 255 Modulus at 100% 1,605 2,305 2,250 2, 240 2,280 2, 390 Tensile retained, percen 72 99 98 99 99 99 Elongation retaine 36 91 87 89 85 84 Light transmission, percent. 18 83 '83 79 66 56 The results summarized in Table VII illustrate that diphenylol propane (composition 2) and diphenylol butane (composition 3) are outstanding stabilizers for plasticized polyvinyl chloride resins. In the presence of these agents the resinous compositions retain their clarity completely and their elastic properties remain substantially unaltered even after severe aging tests. Composition 4 illustrates that slight alkylation of the phenol ring makes the solubility of the bisphenol stabilizer-in the original plastic. composition better as indicated by improved light trans: mission, but the light transmission data after aging indicate that the methylated bisphenol is a less potentstabilizer .than the unalkylated bisphenols. 'Ihisincreasinglv detrimental eifect of alkylation is still further illustrated} to prevent opaqueness is substantially inferior not only.

to its unalkylated homologue, but even to its methylated one.

The adverse effect of chemical complexity on the activity of the bisphenol stabilizer, particularly in regard to its ability to prevent opaqueness, is even more clearly apparent in composition 6 wherein the stabilizer used had the formula H H G C H H OH! OH! OH;

In the presence of this stabilizer a loss of light transmission of about 23% was incurred after 7 days at 100 C., as opposed to a slight actual increase in light transmission in compositions 2 and 3 containing the preferred stabilizer species.

The several examples given above show the effectiveness of a certain class of bisphenol compounds as stabilizers for solid resin-like chlorinated aliphatic hydrocarbons possessing substantially no unsaturation. The essential characteristics of the novel stabilizers are that their two phenol groups are joined together by means of an intervening alkyl group; and that the phenol rings themselves possess an alkylating ability. The latter characteristic requires that each phenol group must have at least three, and preferably four, unsubstituted hydrogens in the ring. And if any substituents are present, the latter must be of relatively small size, e.g., a chlorine atom, or an alkyl radical not larger than propyl. Where the presence of such substituents may be desirable to obtain a stabilizer more readily soluble in the resin, it must be realized that the stabilizer potency is concomitantly reduced by such substitution, and that the ring-substituted bisphenols are, therefore, not true equivalents of the preferred unsubstituted bisphenol stabilizers such as 2,2- bis(4 hydroxyphenyl) propane or 2,2-bis(4-hydroxyphenyl) butane. Usable bisphenols having a substituent on the phenol ring are illustrated by 2,2-bis(4-hydroxy- S-methyl phenyl) propane, 2,2-bis(4-hydroXy-5-isopropyl phenyl) propane and bis(Z-hydroxy-S-chlorophenyl) methane.

However, it will be understood that the foregoing examples have been presented for purposes of illustration rather than limitation, and that various alternatives or modifications thereof are possible without departing from the scope and spirit of the present invention.

We claim:

1. A composition of matter comprising about 100 parts by weight of a chlorine-containing substantially saturated aliphatic resin like solid having a molecular weight above about 250 and having a combined chlorine content of about 25 to 70%, and, as a stabilizer therefor about 0.5 to 5.0 parts by weight of a bisphenol compound having the formula R --XR wherein X is selected from the group consisting of 2,2-alkylidene groups of 3 to 6 carbon atoms, and 3,3-alkylidene groups of 4 to 7 carbon atoms, and wherein R and R are selected from the group consisting of hydroxyphenyl radicals, monochlorinated hydroxyphenyl radicals, and monoalkyl substituted hydroxyphenyl radicals having 1 to 3 carbon atoms per alkyl group.

2. A composition of matter comprising a major proportion of a substantially saturated aliphatic chlorinated hydrocarbon material having a molecular weight above 250 and containing about 25 to 70% of chlorine, said material being selected from the group consisting of polyvinyl chloride, vinyl chloride-vinyl acetate copolymer's, polyvinylidene chloride, chlorinated polyethylene, and

8 chlorinated parafiin wax, and as a stabilizer therefor, 0.1 to 5.0 weight percent based on the weight of said chlorinated hydrocarbon material of a bis-phenol compound having the formula wherein R is an alkyl radical of 1 to 4 carbon atoms and wherein R and R are hydroxyphenyl groups.

3. A composition of matter according to claim 2 where in the bis-phenol compound is 2,2-di(p-hydroxyphenyl) propane.

4. A composition of matter comprising 100 parts by weight of a chlorinated paraffin wax having a chlorine content between 30 to 70%, and 0.5 to 5 parts by weight of 2,2-di(p-hydroxyphenyl) propane as a stabilizer therefor.

5. A composition of matter comprising 100 parts by weight of a resinous vinyl chloride polymer and, as a stirbilizer therefor, 0.1 to 5.0 parts by weight of 2,2-di (p-hydroxyphenyl) propane.

6. A composition of matter comprising 100 parts by weight of a high molecular weight copolymer of about vinyl chloride and 5% vinyl acetate, 15 to 50 parts by weight of a chlorinated parafiin wax having a chlorine content of 30 to 70%, and 1 to 5 parts by weight of 2,2-di(p-hydroxyphenyl) propane as a stabilizer therefor.

7. A composition of matter comprising parts by weight of a resinous copolymer of a major proportion of vinyl chloride and a minor proportion of vinyl acetate, 15 to 50 parts by weight of a high molecular weight copolymer of butadiene and acrylonitrile, 0.5 to 2 parts by weight of 2,2-di(p-hydroxypheny1) propane and 0.5 to 2 percent based on the weight of the nitrile copolymcr of a di-tertiary alkylated cresol having 4 to 5 carbon atoms per alkyl group. i

8. In a method for hot fiuxing a solid butadiene-acryl onitrile polymer and a resinou vinyl chloride polymer, the improvement which comprises carrying out the hot fluxing of the polymers in the presence of minor amounts of both 2,2-bis(p-hydroxyphenyl) propane and 2,6-ditert-butyl-4-methyl phenol.

9. Composition according to claim 1 in which the bisphenol compound is 2,2-bis(4-hydroxy-3-methyl phenyl) propane.

10. A composition of matter comprising about 100 parts by weight of chlorinated polyethylene having a chlorine content between about 30 to 70%, and about 0.5 to 5.0 parts by weight of 2,2-di(p-hydroxyphenyl) propane as a stabilizer therefor.

11. In a method for hot fluxing a nitrile-diolefin polymer with a resinous vinyl chloride-vinyl acetate copolymer, the improvement which comprises carrying out the hot fluxing of the polymers in the presence of a minor.

References Cited in the file of this patent UNITED STATES PATENTS 2,625,521 Fischer Jan. 13, 1953 FOREIGN PATENTS Calcott et a1 Feb. 5, 193s Australia July 20, 1950 

1. A COMPOSITION OF MATTER COMPRISING ABOUT 100 PARTS BY WEIGHT OF A CHLORINE-CONTAINING SUBSTANTIALLY SATURATED ALIPHATIC RESIN LIKE SOLID HAVING A MOLECULAR WEIGHT ABOVE ABOUT 250 AND HAVING A COMBINED CHLORINE CONTENT OF ABOUT 25 TO 70%, AND, AS A STABILIZER THEREFOR ABOUT 0.5 TO 5.0 PARTS BY WEIGHT OF A BISHENOL COMPOUND HAVING THE FORMULA R1-X-R2 WHEREIN X IS SELECTED FROM THE GROUP CONSISTING OF 2,2-ALKYLIDENE GROUPS OF 3 TO 6 CARBON ATOMS, AND 3,3-ALKYLIDENE GROUPS OF 4 TO 7 CARBON ATOMS, AND WHEREIN R1 AND R2 ARE SELECTED FROM THE GROUP CONSISTING OF HYDROXYPHENYL RADICALS, MONOCHLORINATED HYDROXYPHENYL RADICALS, AND MONOALKYL SUBSTITUTED HYDROXYPHENYL RADICALS HAVING 1 TO 3 CARBON ATOMS PER ALKYL GROUP. 